Machine for assembling wires into electrical fixtures



April 7, 1970 H. w. SCHlCK 3,

7 MACHINE FOR ASSEMBLING WIRES INTO ELECTRICAL FIXTURES Filed Ma 1, 196'? :5 Sheets-Sheet 1 FIG. 1

INVENTOR HENRY W. SCHICK ATTORNEYS April 7, 1970 H. w. SCHICK 3,504,416

MACHINE FOR ASSEMBLING WIRES INTO ELECTRICAL FIXTURES Filed May ,1 1967 3 Sheets-Sheet 2 INVENTOR HENRY W. SCHICK ATTORNEYS April 7, 1970 H. w. SCHICK 3,504,416

MACHINE FOR ASSEMBLING WIRES INTO ELECTRICAL FIXTURES Filed May 1, 1967 FIG. 3

3 Sheets-Sheet 5 FIG. 4 22 6 FIG. 5

lmlw=ai 35b n 35a :470 47 k 49 We, .J 350 32 \1 59 I i 73 J "INVENTOR HENRY w. SCHICK BY WJ Q ATTORNEYS United States Patent 3,504,416 MACHINE FOR ASSEMBLING WIRES INTO ELECTRICAL FIXTURES Henry W. Schick, Commack, N.Y., assignor to Gilbert Manufacturing Company, Inc., Long Island City, N.Y.,

a corporation of New York Filed May 1, 1967, Ser. No. 635,244 Int. Cl. HOIr 43/00, 1/00; B23p 19/102 US. Cl. 29203 9 Claims ABSTRACT OF THE DISCLOSURE A machine for assembling current carrying wires into electrical fixtures in which a ram presses a resilient wireretaining insert member through an opening in a support structure of the machine and into locking engagement with a suitable wire-holding channel in the electrical fixture which is positioned at an assembly station beneath the support structure with the channel in the fixture aligned with the opening in the support struc ture, the ram preferably being actuated by the movement of the fixture to the assembly station.

This invention relates to automatic assembly machines in general, and, more particularly, to a simple but effective machine for assembling wires into electrical fixtures such as light sockets. In many types of electrical lighting systems, for example, Christmas tree lighting sets and certain types of outdoor lighting sets, the contact members of a large number of light sockets must be electrically connected to a pair of current carrying wires.

In a conventional manufacturing operation where the light sockets and wires are assembled manually, the cost of the manual labor amounts to a relatively large share of the total manufacturing cost of the lighting system. Therefore it is apparent that effecting savings in the labor portion of the manufacturing costs, such as by the use of automatic assembly machines, would be highly desirable. Consequently, there has been a long-felt need in the art for a simple but effective machine for assembling wires into light sockets.

It is an object of this invention to provide a simple and effective machine for assembling wires into light sockets or other electrical fixtures.

Another object of this invention is to provide a machine for assembling wires into light sockets of the type comprising a husk member and a wire-retaining insert member.

According to the above and other objects the present invention provides an assembly machine for pressing a pair of electrical wires and a Wire-retaining insert member into a suitable channel formed in the base of a light socket husk so that electrical contacts mounted in the husk pierce the insulation of the electrical wires to make an electrical connection with the conductors therein and so that the wire-retaining insert snaps into locking engagement with the base of the husk. The assembly machine includes an insert supporting device for releasably supporting a partially resilient insert member. In a preferred embodiment of the invention the insert supporting device includes a structure having an opening therethrough whose dimensions are slightly less than the dimensions of the resilient insert member so as to support the insert member and yet permit said insert member to be forcibly driven through the opening. The assembly machine of the present invention also includes a husk support which is movable from a loading station to an assembly station adjacent the insert supporting device. A ram is provided for driving the insert member through the opening in the support structure into a channel formed in the base 3,504,416 Patented Apr. 7, 1970 "ice of the husk member. In accordance with a preferred embodiment of the invention the ram is automatically actuated in response to the presence of the husk supporting means at its assembly station. Also, if desired, the assembly machine of the present invention can be provided with automatic feeding of the insert members into position in the insert support structure. Further, the husk supporting device can be automatically moved from its loading station to its assembly station.

Other objects and advantages of the present invention will be apparent from the following detailed description and accompanying drawings which set forth the principles of the invention and, by way of example, the best mode contemplated for applying that principle.

In the drawings:

FIG. 1 shows a front elevational view of the assembly machine of the present invention including a device for automatically feeding insert members to the insert supporting structure;

FIG. 2 shows a side elevational view of the assembly machine of FIG. 1;

FIG. 3 is an enlarged view looking in the direction of line 33 of FIG. 1 showing the insert supporting structure;

FIG. 4 is an enlarged cross-sectional view showing the husk member and husk supporting means at the assembly station prior to the actuation of the ram means along line 4-4 of FIG. 1;

FIG. 5 is an enlarged cross-sectional view as in FIG. 4 showing the relationship of the parts after the actuation of the ram means; and

FIG. 6 is a cross-sectional view taken along the line 66 of FIG. 5.

One type of light socket which is particularly well adapted for use in Christmas tree lighting sets and for other applications of a similar nature is described in U.S. Patent No. 3,372,362 of the present inventor, filed Oct. 6, 1965 and issued March 5, 1968 and assigned to the same assignee. This socket is shown in FIGS. 1-6 and is described in greater detail in the aforesaid application. While the assembly machine of the present invention is described for use with this type of socket, it should be understood that it also can be used for assembling other types of sockets to the current carrying Wires.

Referring to FIGS. 1-6 the socket comprises a husk member 70 having a channel 79 formed in the base thereof for receiving both a pair of current carrying wires 59 and a resilient wire-retaining insert member 30 which is of open construction having side walls 31a and 31b zstnd bottom 32 as shown in greater detail in FIGS. 4 and A pair of electrical contact members 72 and 73 are mounted Within the husk member 70, preferably by force fit, so as to provide electrical contact with a light bulb properly inserted into the socket. The ends of the elec trical contact members 72 and 73 protrude into the channel 79 and have one or more barbs or points for piercing the insulation of the wire. Each pointed end is located so as to be capable of piercing the insulation of only one of the wires and make contact with the current carrying conductor therein. Electrical contact is made by inserting the cover member into the channel 79 thereby forcing the wires 59 onto the sharpened ends of the respective contact members 72 and 73 so that the insulation is penetrated and electrical contact is made. The wire is retained in position by means of the insert member 30 which is provided with locking tabs 35a and 35b which snap into locking engagement with the bottom wall if the husk member when the insert member is driven into the channel 79.

Referring now to FIGURES 1 and 2 for a more detailed description of the structure of the assembly machine of the present invention, a spring-return air cylinder is mounted, as by bolts 11, on a bracket 12 which is in turn mounted or clamped on a cylindrical standard 14 which projects upward from base 15 of the assembly machine. Air cylinder 10 together with bracket 12, standard 14 and base 15 may be of the type manufactured by the Airmite Corporation and designated Airmite AP4. Air cylinder 10 operates a reciprocating ram 17, the end of which has a driver piece 18 attached thereto by one or more set screws 19. Driver piece 18 includes a body portion 21 which encloses and is attached to the lower end of ram 17, and an operating portion 22 which may be specially shaped for proper coaction with insert member 30 of the light socket to be assembled. A member 24 is fastened to ram 17 by means of set screw 25 and extends substantially heorizontally to embrace standard 14 so as to prevent ram 17 from twisting on its axis during operation.

The insert members 30 for the sockets are supported for assembly by a horizontal support piece 41. Support piece 41 is secured by screws 42, for example, to the top of a vertical piece 43 which is mounted on the base 15 of the assembly machine. A track or channel 44 is formed into the upper surface of horizontal piece 41 for accepting insert members 30 from vibrator swirl feed mechanism 50. Vibrator swirl feed mechanism 50 may be of a type well known to those skilled in the art such as, for example, the vibrator swirl feed mechanisms manufactured by the Syntron Corporation.

As shown more clearly in FIG. 3, insert members 30 are fed along track 44 in end to end relation by the action of the feed mechanism pushing additional insert members into the track. A plate 45 is mounted on the upper surface of horizontal piece 41 by, for example, screws 46, and extends partially over channel 44 to form a lip to prevent the insert members 30 from being jiggled or bounced out of track 44 by vibration resulting from the operation of vibrator swirl feed mechanism 50 and ram 17.

As shown more clearly in FIG. 4, the side walls 470! and 47b forming track 44 are chamfered or beveled in order to conform to the slanted sides 33a and 33b of insert members 30. Track 44 terminates in a blind wall 470 forming an assembly station at which a depression 48 formed in the lower surface of horizontal piece 41 meets track 44 to form an opening or driver passageway 49 through piece 41. The resilient or deformable insert members 30 may be driven through opening 49 by the action of ram 17. More particularly, as shown in FIGS. 4 and 5 operating portion 22 of driver piece 18 is sufficiently wide to engage the tops of both side walls 31a and 31b of insert member 30, spanning the open space therebetween and allowing side walls 31a and 31b to flex inward freely. In response to the downward force of operating piece 22, the downwardly tapered surfaces 33a and 33b of side walls 31a and 31b coact with the chamfered or beveled edges 47a and 47b of track 44 to cam the resilient side walls 31a and 31b of insert member 30 inward so as to permit insert member 30 to pass through the driver opening 49 in insert supporting piece 41. Operating portion 22 of driver piece 18 passes through driver opening 49 without obstruction. It will be apparent to those skilled in the art that supporting piece 41 with track 44 and driver opening 49 provides an extremely simple and reliable means for supporting insert members 30 and yet permitting them to be driven directly into channel 79 in husk 70.

As shown in FIG. 2 a husk supporting member 60 rests on a raised portion '61 of base 15 and is movable from a loading position station (position shown in FIG. 2) to an assembly position station immediately beneath the driver passage 49 of horizontal insert supporting piece 41. In the preferred form of the present invention, husk supporting member 60 is moved from the loading station to the assembly station by means of a double-acting air cylinder 62 whose shaft 63 is connected to the husk supporting member. Air cylinder '62 is mounted within an opening 64 in cylindrical standard 14 and is retained in position by a bracket 65 which is secured to standard 14 by bolts 66, for example. Husk supporting member 60 rides in a pair of guide rails 67a and 67b which guides it from the loading station to the assembly station. Rails 67 are mounted on a raised portion 61 of base 15 which slidably engages the lower portion 69 of husk supporting member 60 as it travels between its stations. A crosspiece 670 mounted on guide rails 67a and 67b serves to stop husk supporting member 60 at its assembly station so that channel 79 of husk 70 is precisely located beneath driver opening 49 in insert supporting piece 41. An index piece 71 shown in FIG. 1, is mounted on the upper surface of husk supporting member 60. Piece 71 serves to ensure the precise angular positioning of the husk member 70 of the light socket to be assembled. The precise angular positioning of husk 70, relative to driver passage 49, is ensured by the coaction of sides 74 and 75 of index piece 71 with complementary grooves 77 and 78 formed in the interior surface of husk 70. If the machine operator places husk 70 on support member 60 in the proper angular orientation, sides 74 and 75 of index piece 71 will slip easily into the complementary grooves 77 and 78 formed in the interior surface of husk 70 thus allowing the husk to drop all the way down onto piece 71 so that the open mouth 76 0f husk 70 will be seated firmly against the upper surface of support member 60. On the other hand, if the angular orientation of husk 70 is not correct, sides 74 and 75 of index piece 71 will catch against the interior surface of husk 70 thus preventing the mouth 76 of husk 70 from becoming fully seated against the upper surface of support member 60. This condition will alert the machine operator to re-orient husk 70 to the correct angular position for the assembly operation.

In the preferred form of the present invention shown in FIG. 6, index piece 71 also serves to maintain the proper positioning of electrical contacts 72 and 73, which are preferably mounted by force fit within husk 70, during the assembly operation. More specifically, as shown in FIG. 6, side 74 of index piece 71 is provided with a notch 83 to accommodate electrical contact 73. The end 84 of electrical contact 73 abuts the end 85 of notch 83 so that electrical contact 73 is prevented from being dislodged by the downward pressure of wire 59 during the assembly operation. Similarly, the top 86 of index piece 71 is provided with a downwardly sloping surface 87 to accommodate the bent portion of electrical contact 72 which is to contact the bottom of the bulb base. The end 88 of contact 72 abuts the end wall 89 of surface 87 of index piece 71 so as to maintain contact 72 in position during the assembly operation.

Referring again to FIG. 2, a collar 92 is adjustably mounted on shaft 63 by set screw 94. Collar 92 has a lateral projection '95 (FIG. I) for contacting an operating button 96 of air valve 97. Collar 92 is so positioned along shaft 63 that when the husk supporting member 60 is at its operating station, lateral projection 95 of collar 92 operates control 96 of air valve 97 admitting air under pressure from a reservoir, not shown, through air hoses 98 and 99 to air cylinder 10. When air is admitted ram 17 is actuated to drive insert member 30 into channel 79 of husk member 70 of the light socket to be assembled.

In operation, the machine operator places light socket husk member 70 in position on husk supporting member 60. Hook portion 78 of husk member 70 is preferably oriented outward as shown in FIG. 2 or, alternatively, inward as long as successive light socket husk members 70 are all oriented the same way. The consistent orientation of the light socket husk member 70 ensures that all of the electrical contact members 73 of a set of sockets will be connected to the same lead of wire 59 while all of the other electrical contact members 72 will penetrate the other lead. This arrangement establishes polarity for all contact members as required by the standards of the Underwriters Laboratory for household wiring systems.

The machine operator is aided in the precise angular orientation of husk member 70 by the coaction of the sides 74 and 75 of index piece 71 with complementary grooves in the interior surface of husk member 70 as has been explained in greater detail herein above.

After husk member 70 has been properly seated on husk supporting member 60, the machine operator lays the dual-conductor wire 59 into channel 79 in the base of husk member 70, taking care not to twist wire 59 between one socket and the next. Usually the two leads of wire 59 are of different colors to help establish proper polarity for the set of sockets.

After husk 70 and wire 59 have been properly positioned the machine operator presses a button, lever, or foot pedal (not shown) to admit air under pressure via air hose 90 to double-acting air cylinder 62. The resulting action of air cylinder 62 is to draw shaft 63 inwards until husk supporting member 60 abuts cross piece 670. At this point husk supporting member 60 is properly located at its assembly station beneath opening 49 of insert supporting piece 41. Preferably, there is a resilient, overtravel connection such as a spring (not shown) between shaft 63 and the husk supporting member 60. When husk supporting member 60 stops against cross-piece 67 shaft 63 over-travel and lateral projection 95 of collar 92 operates button 96 of air valve '97 to admit air under pressure to spring-return air cylinder 10. The resulting downward stroke of ram 17 brings operating portion 22 of driver piece 18 into engagement with insert member 30 located at the drive opening 49 thus driving the insert member 30 through the drive opening 49 in insert supporting piece 41 as has been explained in greater detail herein above.

The continued downward stroke of operating piece 22 drives insert member 30 into channel 79 in the base of husk member 70. The downwardly tapered surfaces 33a and 33b of side Walls 31a and 31b coact with the edges 34a and 34b of channel 79 to squeeze the side walls of the insert member 30 until the parts snap into the fully assembled position shown in FIG. 5. In some cases, the walls on either side of channel 79 give slightly to facilitate the fastening of the insert member. As shown in FIG. 5, insert 30 is retained in the assembled position by the engagement of locking surfaces 35a and 35b with the interior surfaces of the buttom wall base of husk 70.

After insert member has been driven into the assembled position within channel 79 of husk 70 the machine operator releases the button, or lever, or foot pedal (not shown) thus causing double acting air cylinder 62 to return husk supporting member 60 to its loading position. Before the husk supporting member 60 starts to move toward its loading station the over-travel connection of shaft 63 to member 60 causes shaft 63 and the lateral projection 95 of collar 92 to move slightly to release control 96 of air valve 97. This releases the pressure from air cylinder and ram 17 returns to its orig inal position in response to the action of the spring return mechanism permitting member 60 to move. The husk supporting member 60 returns to its loading station and the machine operator removes the assembled wire and socket combination and places a new husk member in position for the next assembly operation.

While a manual operation for placing the husks 70 on the supporting member 60 has been described, it should be understood that this also can be done automatically or semi-automatically. For example, in my copending-application S.N. 635,230, filed concurrently herewith, and entitled Apparatus for Orienting Articles, which is assigned to the same assignee, a system is disclosed for orienting husks of the type shown herein to predetermined angular position. The oriented husks can be transported by a suitable conveyor system onto the support ing member 60.

Although the principles of the present invention have been illustrated by reference to the structure and operation of a specific machine for assembling wires into light sockets, it will be appreciated by those skilled in the art that certain changes may be made without departing from these principles. For example, the assembly machine of the present invention may be adapted to assemble items other than electrical light sockets. Further, hydraulic or mechanical means may be substituted for the air cylinders employed in the preferred embodiment. In addition it will be apparent to those skilled in the art that other modifications and adaptations of the apparatus may be made without departing from the spirit and scope of the invention as set forth with particularity in the appended claims.

What is claimed is: 1. An assembly machine for assembling an electrical fixture to a current carrying wire, said electrical fixture comprising a resilient insert member and a husk member having an opening for receiving said current carrying wire and said insert member, said assembly machine comprising:

an insert supporting structure for releasably supporting said insert member, said insert supporting structure having an opening therethrough, the dimensions of said opening being slightly less than the dimensions of said resilient insert member so as to support said insert member and yet permit said insert member to be driven through said opening by said ram means; means for supporting said husk member; means for moving said husk supporting means from a loading station to an assembly station adjacent said insert supporting structure with the wire receiving opening of the husk located in line with the opening of the insert supporting structure; ram means for releasing said insert member from said insert supporting structure and driving said insert member into said opening in said husk member, and

ram actuation means for controllably actuating said ram means.

2. An assembly machine of the type described in claim 1 wherein said husk supporting means includes index means for engaging said husk member to place the insert receiving opening in the proper angular orientation for assembly of the insert member.

3. An assembly machine as set forth in claim 1 further comprising, structure for holding a plurality of insert members, and means for sequentially feeding said insert members to said insert supporting means with the same relative orientation.

4. An assembly machine as set forth in claim 3 wherein said insert members have a recess bounded by at least two upstanding walls and said feeding means orients each said insert member fed to said insert supporting structure with its said recess facing said ram means.

5. An assembly machine as in claim 4 wherein said ram means spans the upstanding walls of said insert member so as to permit said walls to flex inward as said insert member is driven through the opening in said insert supporting structure.

6. An assembly machine as in claim 5 wherein the portion of said ram means engaging the insert member recess is generally rectangular.

7. An assembly machine for assembling an electrical fixture to a current carrying wire, said electrical fixture comprising a wire-retaining insert member having resilient walls with locking members thereon and a husk having an opening formed in its base for receiving said wire and said wire-retaining insert member, said assembly machine comprising:

an insert supporting means having an opening therethrough, the dimensions of said opening being slightly less than the dimensions of said resilient insert member so as to support said insert member and permit said insert member to be forcibly driven through said opening,

means for supporting said husk member base upward,

means for moving said husk supporting means from a loading station to an assembly station immediately beneath the opening in said insert supporting means,

an index piece mounted on said husk supporting means to maintain said husk member in the proper angular orientation for assembly of the insert member thereto,

ram means for driving said insert member through said opening in said insert supporting means into said opening in said husk member so that the locking means engage the bottom wall of the husk member, and

means for actuating said ram means upon movement of said husk supporting means to the assembly station.

8. An assembly machine as in claim 7 wherein the locking members on the insert member have tapered side walls and sides of said opening in said insert supporting means are tapered to conform to the tapered side of said locking members.

9. An assembly machine as in claim 8 wherein said indeX piece is provided with a pair of recesses for receiving the interior ends of electrical contact members mounted in said husk so as to prevent said electrical contacts from becoming dislodged during the assembly operation.

References Cited UNITED STATES PATENTS THOMAS H. EAGER, Primary Examiner US. Cl. X.R. 29206, 235 

